A clay slurry with a solids content of at least about 60 weight percent and a casting rate of at least 60 grams per hour, wherein the slurry contains from about 68 to about 74 weight percent of silica and less than about 0.8 percent of carbon. At least about 9 weight percent of the particles in the
A clay slurry with a solids content of at least about 60 weight percent and a casting rate of at least 60 grams per hour, wherein the slurry contains from about 68 to about 74 weight percent of silica and less than about 0.8 percent of carbon. At least about 9 weight percent of the particles in the slurry are larger than about 44 microns, and at least about 5 weight percent of the particles in said slurry are larger than about 74 microns.
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I claim: 1. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said sl
I claim: 1. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, and wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 2. The clay slurry as recited in claim 1, wherein said ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.53 to about 0.68. 3. The clay slurry as recited in claim 1, wherein said ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.55 to about 0.60. 4. The clay slurry as recited in claim 1, wherein said clay slurry has a solids content of from about 60 to about 65 weight percent. 5. The clay slurry as recited in claim 4, wherein said slurry is comprised of from about 70 to about 74 weight percent of silica. 6. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, wherein from about 55 to about 67 weight percent of the particles in said slurry are smaller than about 2 microns. 7. The clay slurry as recited in claim 6, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 8. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, wherein from about 46 to about 60 weight percent of the particles in said slurry are smaller than about 1 microns. 9. The clay slurry as recited in claim 8, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 05 to about 0.7. 10. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 75 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, wherein from about 37 to about 52 weight percent of the particles in said slurry are smaller than about 0.5 microns. 11. The clay slurry as recited in claim 10, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 46 microns is from about 0.6 to about 0.7. 12. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, and wherein said clay slurry has a loss on ignition of from about 6 to about 7.7 percent. 13. The clay slurry as recited in claim 12, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 14. The clay slurry as recited in claim 12, wherein said clay slurry has a loss on ignition of less than about 7.1. 15. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, and wherein said clay slurry has a settling index of at least about 0.9. 16. The clay slurry as recited in claim 15, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 17. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns, and wherein said clay slurry is comprised of at least about 0.1 weight percent, by weight of said solids, of an organic compound. 18. The clay slurry as recited in claim 17, wherein said organic compound is selected from the group consisting of humic acid, humate, and mixtures thereof. 19. The clay slurry as recited in claim 17, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 20. The slurry as recited in claim 1, wherein said slurry contains at least about 72 weight percent of silica. 21. The slurry as recited in claim 1, wherein said slurry is comprised of organic polyacrylate dispersing agent. 22. The clay slurry as recited in claim 1, wherein said slurry is comprised of sodium silicate dispersing agent. 23. The clay slurry as recited in claim 1, wherein said slurry is comprised of less than about 650 parts per million of soluble sulfate ion. 24. The clay slurry as recited in claim 1, wherein said slurry has a Gallenkamp build up of from about 65 to about 100 degrees. 25. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica and from about 14 to about 21 weight percent of alumina wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns. 26. The clay slurry as recited in claim 25, wherein the ratio of weight percent of said particles that are greater than-about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 27. The clay slurry as recited in claim 25, wherein the ratio of weight percent of said silica to weight percent of said alumina in said slurry is at least about 3.2. 28. The clay slurry as recited in claim 25, wherein the ratio of weight percent of said silica to weight percent of said alumina in said slurry is at least about 4.0. 29. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, less than 0.8 weight percent of carbon, wherein from about 0 to about 30 weight percent of the particles in said slurry are larger than about 45 microns wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns. 30. The clay slurry as recited in claim 29, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 31. The clay slurry as recited in claim 29, wherein said slurry is comprised of less than about 0.7 weight percent of carbon. 32. A clay slurry with a solids content of from 57 about to about 75 weight percent and a casting rate of at least 60 grams per hour, wherein said slurry comprises from about 68 to about 74 weight percent of silica, and wherein at least about 90 weight percent of said silica contains less than about 1017 Si and Si--O silicon-based radicals per gram, wherein at least about 9 weight percent of the particles in said slurry are larger than about 44 microns, and wherein at least about 5 weight percent of the particles in said slurry are larger than about 74 microns. 33. The clay slurry as recited in claim 32, wherein from about 9 to about 30 weight percent of the particles in said slurry are larger than about 45 microns, and wherein from about 5 to about 20 weight percent of the particles in said slurry are larger than about 75 microns. 34. The clay slurry as recited in claim 33, wherein the ratio of weight percent of said particles that are greater than about 75 microns to the weight percent of said particles that are greater than about 45 microns is from about 0.5 to about 0.7. 35. The clay slurry as recited in claim 32, wherein at least about 90 weight percent said silica contains less than about 1016 Si and Si--O silicon based radicals per gram. 36. A casting slip with a solids content of from about 70 to about 75 percent, a casting rate of from about 50 to about 140 grams per 30 minutes, and a modulus of rupture of from about 400 to about 900 pounds per square inch, wherein from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns. 37. The casting slip as recited in claim 36, wherein said casting slip is comprised of from about 71 to about 74 weight percent of solids. 38. The casting slip as recited in claim 37, wherein said casting slip has a casting rate of from about 90 to about 120 grams per 30 minutes. 39. The casting slip as recited in claim 38, wherein said casting slip has a modulus of rupture of from about 420 to about 650 pounds per square inch. 40. The casting slip as recited in claim 38, wherein said casting slip is comprised of from about 8 to about 11 percent of particles greater than 45 microns. 41. The casting slip as recited in claim 40, wherein the ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.3. 42. A casting slip with a solids content of from about 70 to about 75 percent, a casting rate of from about 50 to about 140 grams per 30 minutes, and a modulus of rupture of from about 400 to about 900 pounds per square inch, wherein from about 8 to about 11 weight percent of the particles in said casting slip are greater than about 45 microns. 43. The casting slip as recited in claim 42, wherein said casting slip is comprised of from about 71 to about 74 weight percent of solids. 44. The casting slip as recited in claim 43, wherein said casting slip has a casting rate of from about 90 to about 120 grams per 30 minutes. 45. The casting slip as recited in claim 44, wherein said casting slip has a modulus of rupture of from about 420 to about 650 pounds per square inch. 46. The casting slip as recited in claim 45, wherein said casting slip is comprised of from about 3.5 to about 4.7 percent of particles greater than 75 microns. 47. The casting slip as recited in claim 40, wherein the ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.35. 48. The casting slip as recited in claim 47, wherein said casting slip is comprised of from about 72 to about 74 weight percent of solids. 49. The casting slip as recited in claim 48, wherein said casting slip has a modulus of rupture of from about 440 to about 600. 50. A casting slip with a solids content of from about 70 to about 75 percent and a casting rate of from about 50 to about 140 grams per 30 minutes, wherein: (a) from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns, (b) from about 8 to about 11 percent of particles in said casting slip are greater than 45 microns, and (c) said casting slip has a water absorption of less than about 0.5 percent. 51. The casting slip as recited in claim 50, wherein said casting slip has settling index of at least about 0.90. 52. The casting slip as recited in claim 51, wherein said casting slip has a water absorption of less than about 0.14 percent. 53. The casting slip as recited in claim 52, wherein said casting slip has a settling index of at least about 0.95. 54. A casting slip with a solids content of from about 70 to about 75 percent and a casting rate of from about 50 to about 140 grams per 30 minutes, wherein: (a) from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns, (b) from about 8 to about 11 percent of particles in said casting slip are greater than 45 microns, and (c) said casting slip has a settling index of at least about 0.90. 55. A casting slip with a solids content of from about 70 to about 75 percent and a casting rate of from about 50 to about 140 grams per 30 minutes, wherein: (a) from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns, and (b) said casting slip has a water absorption of less than about 0.5 percent. 56. A casting slip with a solids content of from about 70 to about 75 percent and a casting rate of from about 50 to about 140 grams per 30 minutes, wherein: (a) from about 8to about 11 percent of particles in said casting slip are greater than 45 microns, and (b) said casting slip has a water absorption of less than about 0.5 percent. 57. A casting slip with a solids content of from about 70 to about 75 percent and a casting rate of from about 50 to about 140 grams per 30 minutes, wherein: (a) from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns, (b) from about 8 to about 11 percent of particles in said casting slip are greater than 45 microns, and (c) the ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.3. 58. The casting slip as recited in claim 57, wherein said casting slip has a water absorption of less than about 0.5 percent. 59. The casting slip as recited in claim 57, wherein said casting slip has a water absorption of less than about 0.14 percent. 60. A casting slip with a solids content of from about 70 to about 75 percent, a casting rate of from about 50 to about 140 grams per 30 minutes, and a Gallenkamp buildup that varies less than 5 percent from its initial value after it has been aged for 3 days, wherein at least about 3 weight percent of the particles in said casting slip are greater than about 75 microns. 61. The casting slip as recited in claim 60, wherein from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns. 62. The casting slip as recited in claim 60, wherein said casting slip is comprised of from about 71 to about 74 weight percent of solids. 63. The casting slip as recited in claim 60, wherein said casting slip has a casting rate of from about 90 to about 120 grams per 30 minutes. 64. The casting slip as recited in claim 60, wherein said casting slip has a modulus of rupture of from about 420 to about 650 pounds per square inch. 65. The casting slip as recited in claim 60, wherein said casting slip is comprised of from about 8 to about 11 percent of particles greater than 45 microns. 66. The casting slip as recited in claim 60, wherein said casting slip is comprised of from about 3 to about 5 weight percent of particles greater than about 75 microns, and wherein the ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.3. 67. The casting slip as recited in claim 60, wherein said casting slip has a modulus of rupture of from about 400 to about 900 pounds per square inch. 68. The casting slip as recited in claim 67, wherein said casting slip is comprised of from about 71 to about 74 weight percent of solids. 69. The casting slip as recited in claim 68, wherein said casting slip has a casting rate of from about 90 to about 120 grams per 30 minutes. 70. The casting slip as recited in claim 60, wherein said casting slip is comprised of from about 3.5 to about 4.7 percent of particles greater than 75 microns. 71. The casting slip as recited in claim 70, wherein said casting slip is comprised of from about 8 to about 11 weight percent of particles greater than about 45 microns, and wherein the ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.35. 72. The casting slip as recited in claim 71, wherein said casting slip is comprised of from about 72 to about 74 weight percent of solids. 73. The casting slip as recited in claim 72, wherein said casting slip has a modulus of rupture of from about 440 to about 600. 74. The casting slip as recited in claim 60, wherein said casting slip has a water absorption of less than about 0.5 percent. 75. The casting slip as recited in claim 60, wherein said casting slip has settling index of at least about 0.90. 76. The casting slip as recited in claim 75, wherein said casting slip has a water absorption of less than about 0.5 percent. 77. The casting slip as recited in claim 75, wherein said casting slip has a water absorption of less than about 0.14 percent. 78. The casting slip as recited in claim 77, wherein said casting slip has a settling index of at least about 0.95. 79. A casting slip with a solids content of from about 70 to about 75 percent, a casting rate of from about 50 to about 140 grams per 30 minutes, and a Gallenkamp buildup that varies less than 5 percent from its initial value after it has been aged for 10 days, wherein at least about 3 weight percent of the particles in said casting slip are greater than about 75 microns. 80. The casting slip as recited in claim 79, wherein from about 3 to about 5 weight percent of the particles in said casting slip are greater than about 75 microns. 81. The casting slip as recited in claim 79, wherein said casting slip is comprised of from about 8 to about 11 percent of particles greater than 45 microns. 82. The casting slip as recited in claim 81, wherein said casting slip is comprised of from about 3 to about 5 weight percent of particles greater than about 75 microns, and wherein the ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.3. 83. The casting slip as recited in claim 79, wherein said casting slip is comprised of from about 3.5 to about 4.7 percent of particles greater than 75 microns. 84. The casting slip as recited in claim 82, wherein said ratio of the weight percent of said particles greater than about 75 microns in said casting slip divided by the weight percent of said particles greater than about 45 microns in said casting slip is greater than about 0.35. 85. The casting slip as recited in claim 79, wherein said casting slip has a water absorption of less than about 0.5 percent. 86. The casting slip as recited in claim 79, wherein said casting slip has settling index of at least about 0.90. 87. The casting slip as recited in claim 86, wherein said casting slip has a water absorption of less than about 0.5 percent. 88. The casting slip as recited in claim 86, wherein said casting slip has a water absorption of less than about 0.14 percent. 89. The casting slip as recited in claim 88, wherein said casting slip has a settling index of at least about 0.95. 90. The casting slip as recited in claim 60, wherein said casting slip is comprised of silica, at least 50 weight percent of which contains less than about 1017 Si and Si--O silicon-based radicals per gram. 91. The casting slip as recited in claim 90, wherein at least about 50 weight percent of said silica contains less than about 1016 Si and Si--O silicon based radicals per gram. 92. The casting slip as recited in claim 90, wherein said casting slip is comprised of at least about 60 weight percent of said silica.
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